Small Engine Repair Course

Lesson 1 • Small Engine Types and Applications

Covers two-stroke and four-stroke engine classifications and their common applications. Establishes context for all subsequent repair and diagnostic work.

Lesson 2 • Engine Anatomy and Major Components

Identifies and describes every major engine component and its function. Provides the vocabulary and visual recognition skills needed throughout the course.

Lesson 3 • The Two-Stroke Combustion Cycle

Details port timing, crankcase compression, and fuel-oil mixing in two-stroke engines. Contrasts with four-stroke operation to clarify diagnostic differences.

Lesson 4 • The Four-Stroke Combustion Cycle

Explains intake, compression, power, and exhaust strokes in sequence. Understanding this cycle is prerequisite to diagnosing performance and mechanical faults.

Lesson 1 • Fuel System Components and Flow

Maps fuel flow from tank through filter, pump, and carburetor to combustion chamber. Establishes system-level understanding before component-level service.

Lesson 2 • Carburetor Disassembly and Cleaning

Guides systematic disassembly, ultrasonic or chemical cleaning, and inspection of carburetor parts. Prepares students for accurate reassembly and adjustment.

Lesson 3 • Fuel Injection Basics on Small Engines

Introduces electronic fuel injection systems appearing on newer small engines. Bridges carburetor knowledge to emerging fuel delivery technology.

Lesson 4 • Carburetor Theory and Operation

Explains venturi effect, jets, needle valves, and float operation in carburetors. Connects carburetor function to air-fuel ratio and engine performance.

Lesson 1 • Ignition System Fundamentals

Explains how magneto-based ignition generates and delivers high-voltage spark. Establishes electrical principles needed for all ignition diagnostic work.

Lesson 2 • Ignition Coil Testing and Replacement

Teaches resistance testing, air gap setting, and coil replacement procedures. Connects coil condition to reliable spark delivery and engine starting.

Lesson 3 • Flywheel and Timing Service

Details flywheel removal, key inspection, and timing verification procedures. Flywheel key shear is a common cause of timing faults addressed here.

Lesson 4 • Diagnosing Ignition System Faults

Applies a structured diagnostic process to no-start and misfire conditions. Integrates all ignition components into a systematic fault-isolation workflow.

Lesson 1 • Exhaust System Cleaning and Replacement

Guides carbon removal from exhaust ports, muffler cleaning, and component replacement. Restoring exhaust flow resolves power loss on high-hour engines.

Lesson 2 • Air Filtration System Service

Covers foam, paper, and dual-element filter types, cleaning methods, and replacement criteria. Clean airflow is essential to correct air-fuel ratio and engine longevity.

Lesson 3 • Intake Manifold and Gasket Inspection

Teaches leak detection, gasket replacement, and manifold surface inspection. Intake leaks cause lean conditions that mimic carburetor faults.

Lesson 1 • Oil Pressure Testing and Diagnosis

Covers oil pressure gauge use, acceptable pressure ranges, and low-pressure fault diagnosis. Pressure testing distinguishes pump failure from bearing wear.

Lesson 2 • Lubrication System Types

Compares splash, pressure-fed, and oil-injection lubrication systems across engine types. System type determines service intervals and failure modes.

Lesson 3 • Oil Change and Filter Service

Teaches drain plug removal, filter replacement, and proper fill procedures. Routine oil service is the single most impactful preventive maintenance task.

Lesson 4 • Lubrication Failure Analysis

Analyzes oil consumption, contamination, and bearing failure patterns. Connects lubrication faults to specific internal engine damage for accurate repair planning.

Lesson 1 • Piston, Ring, and Cylinder Service

Covers cylinder bore measurement, honing, ring gap setting, and piston installation. Restoring cylinder geometry eliminates oil consumption and compression loss.

Lesson 2 • Cylinder Head Removal and Inspection

Covers head bolt removal sequence, gasket inspection, and head surface flatness testing. Head condition determines whether resurfacing or replacement is required.

Lesson 3 • Valve Train Service and Lapping

Teaches valve removal, grinding, lapping, and clearance adjustment. Proper valve seating is critical to compression and combustion efficiency.

Lesson 4 • Precision Measurement Tools and Techniques

Teaches micrometer, bore gauge, and feeler gauge use for engine measurement. Accurate measurement is the foundation of every overhaul decision.

Lesson 1 • Electric Starter Motor Service

Teaches starter motor testing, brush inspection, and drive gear service. Electric starters require both mechanical and basic electrical diagnostic skills.

Lesson 2 • Battery Maintenance and Safety

Addresses battery types, electrolyte service, terminal cleaning, and safe jump-starting. Proper battery care extends service life and prevents electrical damage.

Lesson 3 • Charging System Diagnosis

Covers stator output testing, rectifier-regulator function, and battery charging verification. A failed charging system drains batteries and disables electric start.

Lesson 4 • Mechanical Governor Operation and Service

Explains flyweight governor mechanics, linkage geometry, and speed adjustment. Governor faults cause surging, hunting, or overspeed conditions.

Lesson 1 • No-Start Diagnostic Workflow

Applies spark, fuel, compression, and timing checks in an efficient no-start sequence. Integrates all prior system knowledge into a unified diagnostic approach.

Lesson 2 • Performance Testing After Repair

Teaches post-repair run-in procedures, load testing, and performance verification. Confirms repair quality before returning equipment to the customer.

Lesson 3 • Structured Diagnostic Process

Introduces a five-step diagnostic method: verify, gather data, analyze, test, and confirm repair. Systematic process reduces misdiagnosis and unnecessary parts replacement.

Lesson 4 • Preventive Maintenance Scheduling

Builds hour-based and calendar-based maintenance schedules for common equipment types. Proactive maintenance reduces downtime and extends engine service life.